DE102012220305A1 - Sandwich component, useful for motor vehicle, comprises plastic layer having visible surface, fiber-reinforced layers formed on visible surface in opposed side of plastic layer, and core placed in the fiber-reinforced layers - Google Patents
Sandwich component, useful for motor vehicle, comprises plastic layer having visible surface, fiber-reinforced layers formed on visible surface in opposed side of plastic layer, and core placed in the fiber-reinforced layers Download PDFInfo
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- DE102012220305A1 DE102012220305A1 DE201210220305 DE102012220305A DE102012220305A1 DE 102012220305 A1 DE102012220305 A1 DE 102012220305A1 DE 201210220305 DE201210220305 DE 201210220305 DE 102012220305 A DE102012220305 A DE 102012220305A DE 102012220305 A1 DE102012220305 A1 DE 102012220305A1
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Abstract
Description
Die vorliegende Erfindung betrifft ein Sandwichbauteil für ein Kraftfahrzeug mit einer Kunststoffschicht, die eine sichtbare Oberfläche aufweist und einer Faserverbundschicht, die auf einer der sichtbaren Oberfläche gegenüberliegenden Seite der Kunststoffschicht angeordnet ist.The present invention relates to a sandwich component for a motor vehicle with a plastic layer which has a visible surface and a fiber composite layer, which is arranged on one of the visible surface opposite side of the plastic layer.
Um nachhaltige und verbrauchsarme Fahrzeuge herzustellen, wird bei heutigen Kraftfahrzeugen versucht, das Gesamtgewicht auf ein Mindestmaß zu reduzieren. Ein Ansatz liegt darin, das Blech der Außenhautbauteile durch geeignete leichte Kunststoffe zu ersetzen. Aus dem Stand der Technik sind Faserverbundaußenhautbauteile bekannt, die bislang bei sportlich ambitionierten Fahrzeugen eingesetzt werden. Solche Außenhautbauteile wurden insbesondere für Klappen, beispielsweise Motorhauben, Kofferraumdeckel und Türen, sowie zur Herstellung von Dachpartien verwendet. Da es sich bei den erwähnten Fahrzeugen um sehr hochpreisige Produkte handelt, konnten die dabei verwendeten Außenhautbauteile als einzel- oder kleinstseriengefertigte Bauteile hergestellt werden. Die aus diesem Stand der Technik bekannten Bauteile und Herstellungsverfahren sind jedoch nicht geeignet für Großserienfertigungen. Ein wesentlicher Nachteil dieser Bauteile liegt auch darin, dass eine ausreichende Güte der Oberfläche, um den Anforderungen an Außenhautbauteilen von Kraftfahrzeugen zu genügen, nur mit großem Aufwand realisierbar ist.In order to produce sustainable and low-consumption vehicles, today's motor vehicles are trying to reduce the total weight to a minimum. One approach is to replace the sheet metal of the skin components with suitable lightweight plastics. Fiber composite outer skin components are known from the prior art, which are previously used in sporty ambitious vehicles. Such skin components have been used in particular for flaps, such as hoods, trunk lids and doors, as well as for the production of roof sections. Since the vehicles mentioned are very high-priced products, the outer skin components used in the process could be produced as individual or small-batch-produced components. However, known from this prior art components and manufacturing processes are not suitable for mass production. A major disadvantage of these components is also that a sufficient quality of the surface to meet the requirements for outer skin components of motor vehicles, can only be realized with great effort.
Aufgabe der vorliegenden Erfindung ist es, ein Bauteil anzugeben welches sich gegenüber bekannten Außenhautbauteilen aus Blech durch besonders geringes Gewicht auszeichnet, die Anforderungen einer Class-A-Oberfläche erfüllt und ohne zusätzliche Anpassungen in den bekannten Herstellungsprozess bei der Karosseriefertigung integriert werden kann.Object of the present invention is to provide a component which is distinguished from known outer skin components made of sheet metal by particularly low weight, meets the requirements of a Class-A surface and can be integrated without additional adjustments in the known manufacturing process in the Karosseriefertigung.
Diese Aufgabe wird durch eine Vorrichtung mit den Merkmalen des unabhängigen Anspruchs 1 gelöst. Die abhängigen Ansprüche stellen vorteilhafte Ausführungsformen der Erfindung dar.This object is achieved by a device having the features of independent claim 1. The dependent claims represent advantageous embodiments of the invention.
Zur Lösung dieser Aufgabe schlägt die Erfindung ein Sandwichbauteil für ein Kraftfahrzeug vor, mit einer Kunststoffschicht, die eine sichtbare Oberfläche aufweist, einer Faserverbundschicht, die auf einer der sichtbaren Oberfläche gegenüberliegenden Seite der Kunststoffschicht angeordnet ist und einem Kern, der an der Faserverbundschicht angeordnet ist, wobei der Kern aus einem Metallschaum mit einer offenporigen Struktur ausgebildet ist. Durch die offenporige Struktur sind alle Poren bzw. einzelnen Luftkammern zu einem großen Luftvolumen miteinander verbunden. Diese offenporige Struktur ähnelt der Ausbildung eines Fliegenschwamms, wie er zum Reinigen von Verunreinigungen an Fahrzeugen bekannt ist und bietet den Vorteil, dass bei Temperatur- oder Druckbeaufschlagung des Sandwichbauteils Luft oder ein anderes Fluid, welches sich in den Poren befindet, entweichen kann ohne auf die Kunststoffoberfläche Druck auszuüben und diese dadurch zu verformen.To achieve this object, the invention proposes a sandwich component for a motor vehicle, having a plastic layer which has a visible surface, a fiber composite layer which is arranged on an opposite side of the plastic layer to the visible surface and a core which is arranged on the fiber composite layer, wherein the core is formed of a metal foam having an open-pored structure. Due to the open-pore structure all pores or individual air chambers are connected to a large volume of air. This open-pore structure resembles the formation of a fly sponge, as it is known for cleaning contaminants on vehicles and has the advantage that when the temperature or pressure of the sandwich component air or other fluid, which is located in the pores, can escape without the To exert pressure on the plastic surface and thereby deform it.
Weiterhin kann die Kunststoffschicht aus Polyurethan oder einem Epoxidharz ausgebildet sein. Polyurethane oder Epoxidharze haben den Vorteil, dass sie temperaturbeständig sind und bei Beaufschlagung mit Temperatur eine gewisse Reststabilität aufweisen, wodurch die Oberfläche der Kunststoffschicht ihre vorbestimmte Form behält.Furthermore, the plastic layer may be formed of polyurethane or an epoxy resin. Polyurethanes or epoxy resins have the advantage that they are temperature resistant and have a certain residual stability when exposed to temperature, whereby the surface of the plastic layer retains its predetermined shape.
Weiterhin kann das Sandwichbauteil dadurch gekennzeichnet sein, dass die Kunststoffschicht und die Faserverbundschicht stoffschlüssig miteinander verbunden sind. Mit anderen Worten, die Kunststoffschicht und die Matrix der Faserverbundschicht sind aus dem gleichen Material ausgebildet, nämlich Polyurethan oder Epoxidharz. Dadurch kann eine besonders innige und robuste Verbindung zwischen der Kunststoffschicht und der Faserverbundschicht erzeugt werden.Furthermore, the sandwich component may be characterized in that the plastic layer and the fiber composite layer are bonded together in a material-locking manner. In other words, the plastic layer and the matrix of the fiber composite layer are formed of the same material, namely polyurethane or epoxy resin. As a result, a particularly intimate and robust connection between the plastic layer and the fiber composite layer can be produced.
Weiterhin kann der Kern zwischen einer ersten Faserverbundschicht, die mit der Kunststoffschicht in Verbindung steht, und einer zweiten Faserverbundschicht angeordnet sein, wobei die zweite Faserverbundschicht auf einer der ersten Faserverbundschicht gegenüberliegenden Seite des Kerns angeordnet ist. Die zweite Faserverbundschicht verstärkt den Aufbau der Sandwichstruktur, so dass ein besonders robustes Sandwichbauteil realisiert wird.Furthermore, the core can be arranged between a first fiber composite layer, which is in contact with the plastic layer, and a second fiber composite layer, wherein the second fiber composite layer is arranged on an opposite side of the core from the first fiber composite layer. The second fiber composite layer enhances the structure of the sandwich structure, so that a particularly robust sandwich component is realized.
Darüber hinaus kann in der zweiten Faserverbundschicht mindestens ein Durchlass vorgesehen sein, welcher die offenporige Struktur des Kerns mit der Umgebung des Sandwichbauteils fluidisch verbindet. Der Durchlass bietet den Vorteil, dass selbst bei einer geschlossenen Umkapselung des Kernes mit Faserverbundmaterial ein sich in den Poren des Kerns bildender Druck entweichen kann, da Fluide, wie Luft oder Flüssigkeiten, über die Durchlassöffnungen aus dem Kern entweichen.In addition, at least one passage may be provided in the second fiber composite layer, which fluidly connects the open-pored structure of the core with the surroundings of the sandwich component. The passage offers the advantage that even with a closed encapsulation of the core with fiber composite material, a pressure forming in the pores of the core can escape because fluids, such as air or liquids, escape from the core via the passage openings.
Die Faserverbundschichten können mehrlagig aufgebaut sein. Dies bietet den Vorteil, dass durch die Wahl der Anzahl und Ausrichtung der einzelnen Faserlagen die mechanischen Eigenschaften der Faserverbundschicht und damit die mechanischen Eigenschaften des Sandwichbauteils auf die gewünschten Lastfälle einstellbar sind.The fiber composite layers can be constructed in multiple layers. This offers the advantage that the mechanical properties of the fiber composite layer and thus the mechanical properties of the sandwich component can be adjusted to the desired load cases by selecting the number and orientation of the individual fiber layers.
Im Folgenden sollen die Vorteile der vorliegenden Erfindung kurz zusammengefasst werden. Durch die Verwendung der offenporigen Metallstruktur können eingeschlossene Luftvolumen bei Erwärmung expandieren. Die verwendeten Kunststoffe für die Kunststoffschicht sowie die verwendete Matrix der Faserverbundschicht bleibt bei Erwärmung ebenfalls hart und erweicht nicht. Dadurch können Verformungen und Welligkeiten im Bauteil verhindert werden wodurch die sichtbare Oberfläche nicht beschädigt wird. Ein solches Bauteil kann folglich eine kathodische Tauchlackierung durchlaufen und hält auch den sich daran anschließenden Temperaturen im Lacktrocknungsprozess von ca. 220°C Stand. Die offenporige Metallstruktur weist dabei zusätzlich den Vorteil auf, dass die Flüssigkeit aus der kathodischen Tauchlackierung in die Zwischenräume eindringen kann und anschließend wieder herausfließt. Somit saugt sich das Bauteil nicht voll, wie dies beispielsweise bei der Verwendung von Wabenkernen aus Papier oder Kunststoff der Fall wäre. Auch die Gefahr von Korrosion des Kernes kann eliminiert werden, da diese durch die KTL-Bäder hindurch geleitet wird und somit mit einem Korrosionsschutz beschichtet wird. Durch die Verwendung von temperaturstabilen Epoxidharzen oder Polyurethansystemen haben diese eine Reststabilität im Trocknerofen, so dass sich weder die Faserverbundschicht noch die Kunststoffschicht verformen. Auch der Kern aus Metallschaum bietet eine genügende Stabilität gegenüber der Temperaturbeaufschlagung im Trockner. Durch die niedrige Viskosität der KTL-Flüssigkeit verkleben die Schaumporen nicht und ein Zu- und Ablauf ist gewährleistet. Dadurch werden in Verbindung mit der geeigneten Matrix der Faserverbundschicht aus Epoxid, Phenol oder Polyurethan preisgünstige Faserverbundaußenhautteile möglich, die im normalen Lackprozess lackierbar sind. Zudem sind die Eigenschaften in Bezug auf das Crash-Verhalten und den Fußgängerschutz partiell einstellbar, indem der Kern, wie auch die Faserverbundschichten, aus mehreren Einzellagen herstellbar sind. Da die Kunststoffschicht und die Faserverbundbauteile aus dem gleichen Material bestehen, können diese eine feste, stoffschlüssige Verbindung eingehen, ohne dass zusätzliche Arbeitsgänge nötig wären. Dadurch können die erfindungsmäßen Sandwichbauteile direkt lackiert werden. Das bedeutet, sie werden zuerst an die Karosseriestruktur montiert und durchlaufen zusammen mit der Karosserie und den anderen Anbauteilen das KTL-Bad.In the following, the advantages of the present invention will be briefly summarized. The use of the open-pored metal structure can include trapped air volumes Warming expand. The plastics used for the plastic layer and the matrix of the fiber composite layer used also remains when heated and does not soften. This prevents deformation and waviness in the component, which does not damage the visible surface. Such a component can consequently undergo a cathodic dip coating and also keeps the adjoining temperatures in the paint drying process of about 220 ° C. Stand. The open-pore metal structure has the additional advantage that the liquid from the cathodic dip painting can penetrate into the interstices and then flows out again. Thus, the component does not suck fully, as would be the case for example with the use of honeycomb cores made of paper or plastic. Also, the risk of corrosion of the core can be eliminated, as it is passed through the cathodic dip baths and thus coated with a corrosion protection. By using temperature-stable epoxy resins or polyurethane systems, these have a residual stability in the drying oven, so that deform neither the fiber composite layer nor the plastic layer. The core of metal foam offers sufficient stability against the temperature in the dryer. Due to the low viscosity of the KTL liquid, the foam pores do not stick together and an inlet and outlet is guaranteed. As a result, in conjunction with the suitable matrix of the fiber composite layer of epoxy, phenol or polyurethane, low-cost fiber composite skin parts are possible, which can be painted in the normal paint process. In addition, the properties in terms of crash behavior and pedestrian protection are partially adjustable by the core, as well as the fiber composite layers can be produced from several individual layers. Since the plastic layer and the fiber composite components are made of the same material, they can form a solid, cohesive connection, without additional operations would be necessary. As a result, the sandwich components according to the invention can be painted directly. This means that they are first mounted to the body structure and go through together with the body and the other attachments the KTL bath.
Nach dem KTL-Bad werden sie einem Trocknungsprozess unterworfen, bei dem die Bauteile einer Temperatur von ca. 220°C ausgesetzt sind. Anschließend erfolgen die Lackierung sowie ein weiterer Trocknungsschritt, in dem der Lack mit bis zu 160°C getrocknet wird. Dies ist möglich, da der Metallschaum des Kerns auch im Trocknerofen nach dem KTL-Bad die Gestaltfestigkeit beibehält.After the KTL bath, they are subjected to a drying process in which the components are exposed to a temperature of approx. 220 ° C. Subsequently, the painting and a further drying step, in which the paint is dried at up to 160 ° C. This is possible because the metal foam of the core also retains the structural strength in the drying oven after the cathodic dip bath.
Im Folgenden wird die Erfindung anhand der Figurenbeschreibung näher erläutert. Die Ansprüche, die Figuren und die Beschreibung enthalten eine Vielzahl von Merkmalen, die im Folgenden im Zusammenhang mit beispielhaft beschriebenen Ausführungsformen der vorliegenden Erfindung erläutert werden. Der Fachmann wird diese Merkmale auch einzeln und in anderen Kombinationen betrachten, um weitere Ausführungsformen zu bilden, die an entsprechende Anwendungen der Erfindung angepasst sind.The invention is explained in more detail below with reference to the description of the figures. The claims, the figures, and the description include a variety of features that will be discussed below in conjunction with exemplary embodiments of the present invention. The person skilled in the art will also consider these features individually and in other combinations to form further embodiments that are adapted to corresponding applications of the invention.
Es zeigen in schematischer DarstellungIt show in a schematic representation
Das Sandwichbauteil
Darunter befindet sich ein Kern
Zur Erhöhung der strukturmechanischen Eigenschaften des Sandwichbauteils
In
In beiden Ausführungsformen kann der Metallschaum über seine geometrische Ausbreitung hinweg, je nach Auftragsmaterial und Dicke des Kerns
Im Folgenden soll das Herstellungsverfahren anhand der
In diesem zweiten Verfahrensschritt, wie in
In dem dritten Verfahrensschritt wird ein Kern
Optional kann in einem vierten Verfahrensschritt eine zweite Faserverbundschicht
In dem fünften Verfahrensschritt wird, wie in
In einer weiteren Alternative des Verfahrens, kann vor dem fünften Verfahrensschritt auf eine Oberfläche der oberen Werkzeughälfte
ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION
Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.
Zitierte PatentliteraturCited patent literature
- WO 01/00355 A1 [0025] WO 01/00355 A1 [0025]
Claims (8)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE201210220305 DE102012220305A1 (en) | 2012-11-08 | 2012-11-08 | Sandwich component, useful for motor vehicle, comprises plastic layer having visible surface, fiber-reinforced layers formed on visible surface in opposed side of plastic layer, and core placed in the fiber-reinforced layers |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE201210220305 DE102012220305A1 (en) | 2012-11-08 | 2012-11-08 | Sandwich component, useful for motor vehicle, comprises plastic layer having visible surface, fiber-reinforced layers formed on visible surface in opposed side of plastic layer, and core placed in the fiber-reinforced layers |
Publications (1)
Publication Number | Publication Date |
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DE102012220305A1 true DE102012220305A1 (en) | 2014-05-08 |
Family
ID=50489810
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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DE201210220305 Withdrawn DE102012220305A1 (en) | 2012-11-08 | 2012-11-08 | Sandwich component, useful for motor vehicle, comprises plastic layer having visible surface, fiber-reinforced layers formed on visible surface in opposed side of plastic layer, and core placed in the fiber-reinforced layers |
Country Status (1)
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DE (1) | DE102012220305A1 (en) |
Cited By (4)
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---|---|---|---|---|
EP3037259A1 (en) * | 2014-12-22 | 2016-06-29 | Magna Steyr Fahrzeugtechnik AG & Co KG | Sandwich component |
WO2016146571A1 (en) * | 2015-03-17 | 2016-09-22 | Rheinmetall Landsysteme Gmbh | Protective structure for an armored vehicle |
DE102016104603A1 (en) | 2015-12-28 | 2017-06-29 | FORMTEC PUR-Verarbeitungs-GmbH | Composite component and method of manufacture |
DE202022101648U1 (en) | 2022-03-29 | 2023-07-03 | MöllerWerke GmbH | machine casing |
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WO2001000355A1 (en) | 1999-06-23 | 2001-01-04 | Grillo-Werke Ag | Zinc-based metal foamed bodies |
DE10101649C1 (en) * | 2001-01-16 | 2002-08-29 | Daimler Chrysler Ag | Structural element reinforced with metal foam |
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DE10349693B3 (en) * | 2003-10-24 | 2005-03-24 | Ise Innomotive Systems Europe Gmbh | Rollover safety body for convertible car has a reinforcing structure in cavity which may be free until under preset load |
DE102004012990A1 (en) * | 2004-04-30 | 2005-11-24 | Girlich, Dieter, Dr. | Composite material e.g. for producing ceramic-metallic, made from open-porous metal foam with its pores completely or partly filled out with material and pores of open-porous metal foam are filled of different ceramic materials |
DE102006056167A1 (en) * | 2006-11-28 | 2008-05-29 | Fachhochschule Landshut | Lightweight molding and corresponding manufacturing process |
DE102007027591A1 (en) * | 2007-05-02 | 2008-11-06 | Bombardier Transportation Gmbh | Lining for a rail vehicle comprises a lining element having a first section and a neighboring second section |
DE102010056211A1 (en) * | 2009-12-22 | 2011-06-30 | Mehnert, Jens, Dr., 08468 | Machine cover for protecting machine component of sliding door, has covering units including outer/bearing layer, intermediate layer, functional layer and wearing course/sealing layer |
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2012
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WO2001000355A1 (en) | 1999-06-23 | 2001-01-04 | Grillo-Werke Ag | Zinc-based metal foamed bodies |
DE10101649C1 (en) * | 2001-01-16 | 2002-08-29 | Daimler Chrysler Ag | Structural element reinforced with metal foam |
DE10252475A1 (en) * | 2002-11-12 | 2004-05-27 | Volkswagen Ag | Double-shell bodywork structure with a metal main frame for a motor vehicle comprises inner and outer plastic shells whose front and rear end sections are shaped as three-dimensional ellipsoidal elements |
DE10349693B3 (en) * | 2003-10-24 | 2005-03-24 | Ise Innomotive Systems Europe Gmbh | Rollover safety body for convertible car has a reinforcing structure in cavity which may be free until under preset load |
DE102004012990A1 (en) * | 2004-04-30 | 2005-11-24 | Girlich, Dieter, Dr. | Composite material e.g. for producing ceramic-metallic, made from open-porous metal foam with its pores completely or partly filled out with material and pores of open-porous metal foam are filled of different ceramic materials |
DE102006056167A1 (en) * | 2006-11-28 | 2008-05-29 | Fachhochschule Landshut | Lightweight molding and corresponding manufacturing process |
DE102007027591A1 (en) * | 2007-05-02 | 2008-11-06 | Bombardier Transportation Gmbh | Lining for a rail vehicle comprises a lining element having a first section and a neighboring second section |
DE102010056211A1 (en) * | 2009-12-22 | 2011-06-30 | Mehnert, Jens, Dr., 08468 | Machine cover for protecting machine component of sliding door, has covering units including outer/bearing layer, intermediate layer, functional layer and wearing course/sealing layer |
Cited By (7)
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EP3037259A1 (en) * | 2014-12-22 | 2016-06-29 | Magna Steyr Fahrzeugtechnik AG & Co KG | Sandwich component |
CN106182947A (en) * | 2014-12-22 | 2016-12-07 | 马格纳斯泰尔汽车技术两合公司 | Sandwich component |
RU2635225C2 (en) * | 2014-12-22 | 2017-11-09 | Магна Штайр Фарцойгтехник Аг Унд Ко. Кг | Multilayered part |
US10300676B2 (en) | 2014-12-22 | 2019-05-28 | Magna Steyr Fahrzeugtechnik Ag & Co Kg | Sandwich component |
WO2016146571A1 (en) * | 2015-03-17 | 2016-09-22 | Rheinmetall Landsysteme Gmbh | Protective structure for an armored vehicle |
DE102016104603A1 (en) | 2015-12-28 | 2017-06-29 | FORMTEC PUR-Verarbeitungs-GmbH | Composite component and method of manufacture |
DE202022101648U1 (en) | 2022-03-29 | 2023-07-03 | MöllerWerke GmbH | machine casing |
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